Method of increasing the output of a transfer film upon embossing and apparatus suitable for same

ABSTRACT

There is described a method of increasing the output of a transfer film ( 1 ) upon embossing, in particular hot embossing, wherein the transfer film ( 1 ) has a carrier film ( 1   a ) and a transfer layer portion ( 1   b ) which is releasable from the carrier film ( 1   a ). During a first embossing operation first regions ( 10 ) of the transfer layer portion ( 1   b ) which are arranged removed from each other at a spacing a are transferred by means of a first embossing tool from the transfer film ( 1 ) onto at least one substrate ( 2 ), wherein first openings ( 10   a ) are produced at the spacing a in the transfer layer portion ( 1   b ) of the transfer film ( 1 ). After the first embossing operation the transfer film ( 1 ) is wound up after the first embossing operation and fed to at least a further embossing operation.

This application claims priority based on an International Applicationfiled under the Patent Cooperation Treaty, PCT/EP2008/004697, filed onJun. 12, 2008 and German Application No. DE 102007027493.0-27, filed onJun. 14, 2007.

BACKGROUND OF THE INVENTION

The invention concerns a method of increasing the output of a transferfilm upon embossing, in particular hot embossing, wherein the transferfilm has a carrier film and a transfer layer portion which is releasablefrom the carrier film, wherein during a first embossing operation firstregions of the transfer layer portion which are arranged removed fromeach other at a spacing a are transferred by means of a first embossingtool from the transfer film onto at least one substrate, wherein firstopenings are produced at the spacing a in the transfer layer portion ofthe transfer film.

In the operation of embossing on cards of paper or plastic material forthe mass production of bankcards, credit cards, telephone cards, drivinglicense cards, identity cards and the like, regions of a transfer layerportion of a transfer film are embossed onto a card substrate by meansof known card production apparatuses, for example of the “Cardline” typefrom Atlantic Zeiser, with up to 40,000 cards per hour being embossed.To achieve such high levels of embossing output a hot rolling embossingmethod is usually employed, in which an embossing wheel whose surfacehas raised segments in the shape of the regions to be embossed out ofthe transfer layer portion of the transfer film is used. The embossingwheel is also usually followed by a cooling device to which the embossedcard substrate and the transfer film still adhering to the cardsubstrate is fed for being cooled down before the transfer film isseparated from the card substrate. In the operation of separating thecard substrate and the transfer film the regions of the transfer layerportion which have been embossed onto the card surface remain on thecard substrate. The transfer film which is pulled off only still has onthe carrier film the part of the transfer layer portion, which was notfixed on the card surface. After the embossing operation therefore thisinvolves a carrier film with a transfer layer portion having holes, as awaste product.

The card substrates are usually fed to the apparatus with a transportdevice, transport chains involving a constant chain pitch frequentlybeing employed. In that case the transfer film is used over a lengthcorresponding to the respective chain pitch for each individual card,independently of the regions which are actually to be embossed out ofthe transfer film. After the embossing operation a relatively largeremainder of transfer layer portion is left unused on the carrier film.In the case of a mass-produced item such as a card, in spite of therelatively high costs for transfer films, it is only possible to achievelow prices for each card so that card manufacture which is as economicalas possible is required.

To make better use of a transfer film, a relatively complicated andexpensive apparatus has already been proposed in accordance with EP 0673 317 B1, in which the transfer film can be simultaneously used forembossing on a plurality of substrates arranged in mutually juxtaposedrelationship in the transport direction, using a direction-changingarrangement.

SUMMARY OF THE INVENTION

Therefore the object of the invention is further to improve the economyof embossing processes in terms of the utilization of transfer films andto provide a method suitable for that purpose and a simple apparatus.

According to the invention the object is attained for a method ofincreasing the output of a transfer film upon embossing, in particularhot embossing, wherein the transfer film has a carrier film and atransfer layer portion which is releasable from the carrier film,wherein during a first embossing operation first regions of the transferlayer portion which are arranged removed from each other at a spacing aare transferred by means of a first embossing tool from the transferfilm onto at least one substrate, wherein first openings are produced atthe spacing a in the transfer layer portion of the transfer film, andwherein the transfer film is wound up after the first embossingoperation and fed to at least a further embossing operation in whichsecond regions of the transfer layer portion respectively arrangedbetween two first openings are transferred from the transfer film ontoat least one further substrate by means of a second embossing tool,wherein second openings are produced in the transfer layer portion ofthe transfer film, arranged at a spacing from the first openings.

The object is attained for an apparatus for carrying out the methodaccording to the invention, which has the following units:

-   -   a transfer film storage means which provides the transfer film        in wound-up form,    -   an embossing tool which forms the first and second embossing        tool and to which the transfer film is fed from the transfer        film storage means, and    -   a transfer film take-up means onto which the transfer film        inclusive of the first openings is wound after the first        embossing operation,

wherein arranged between the embossing tool and the transfer filmtake-up means is a first sensor unit which by means of at least onefirst sensor detects a position of the first openings in the transferlayer portion of the transfer film prior to the step of winding onto thetransfer film take-up means in the form of first control data and thatarranged between the transfer film storage means and the embossing toolis a second sensor unit which by means of at least one further sensordetects a position of the first openings in the transfer layer portionof the transfer film prior to the at least one further embossingoperation in the form of second control data.

The transfer film which was originally discarded as waste after thefirst embossing operation, with the transfer layer portion having thefirst openings, is accordingly used at least a second time. In this casethe used transfer film, with a sufficient spacing between the firstopenings, can either be used once again in the same embossing process orit can be used for other embossing processes in which regions ofdifferent shape are embossed out of the transfer layer portion. That ispossible if the transfer film is wound up uniformly and particularlycarefully after the first embossing operation so that the transfer filmdoes not suffer from any fold formation or excessive deformation.Partial detachment from the carrier film or damage to the transfer layerportion on the transfer film which has already been used once is to beavoided in order to be able to carry out the at least one furtherembossing operation with as little trouble as possible.

In that respect it is particularly preferred for the transfer film to beused twice, but upon suitably careful handling of the transfer filmwhich has been used, it is also possible to follow that with stillfurther embossing operations.

It is particularly preferred if the first embossing tool is used againas the second embossing tool. After the first embossing operation thetransfer film coil which has already been used once is accordingly usedagain and fed again to the apparatus which has already been used once,with the first embossing tool. That is possible if a sufficiently largeregion of transfer layer portion remains between the first openings, forsecond openings, the dimensions of which correspond to those of thefirst openings.

It has accordingly proven to be desirable if the first openings and thesecond openings are of the same size. However it is also possible toform first and second openings of different sizes or of differentshapes.

It is advantageous if a first opening and an adjacent second opening areformed spaced from each other by at least 0.5 mm, in particular at least1 mm. That avoids an overlap of first and second openings which wouldlead to incomplete embossing on the at least one further substrate.Furthermore detachment of thin limb portions of the transfer layerportion between two adjacent openings is reliably avoided, whenunwinding the transfer film which has already been used.

It has also proven desirable if the at least one substrate and the atleast one further substrate are used with the same dimensions. Thus forexample the same card substrates can be processed in the first embossingoperation, as in the at least one further embossing operation.

In regard to an implementation which can be controlled as well aspossible in respect of the at least one further embossing operation, ithas proven desirable if the spacing a between two adjacent firstopenings is kept constant over the entire length of the transfer film.It is necessary also to provide for that if a machine stoppage oranother fault occurs during the first embossing operation.

In that respect it has proven to be advantageous if a position of thefirst openings in the transfer layer portion of the transfer film isdetected in a first sensor unit by means of at least one first sensor inthe form of first control data.

During the first embossing operation preferably a sequence of movements,in particular a speed and/or a spatial position, of the first embossingtool and/or of the transfer film and/or of a transport device fortransporting the at least one substrate is regulated by means of thefirst control data.

To implement positioning of the second openings during the at least onefurther embossing operation in correct positional relationship, inparticular a position of the first openings in the transfer layerportion of the transfer film is detected before the at least one furtherembossing operation in a second sensor unit which has at least onesensor in the form of second control data.

The second sensor unit preferably has in total three further sensors,wherein the position of a first opening is determined by means of twosensors and a position of the second opening to be formed in adjacentrelationship with said first opening is ascertained by means of thethird sensor. As slight stretching or distortion of the transfer filmcan occur when winding up the used transfer film, it is no longer to beassumed that there is a constant spacing a between the first openingswhen carrying out the at least one further embossing operation butrather the spacings which are really present between the first openingsand the lengthwise dimensions which really occur in respect of the firstopenings must be taken into consideration.

The sensors of the first sensor unit and/or the second sensor unit arepreferably optical sensors.

It is preferable if during the at least one further embossing operationa sequence of movements, in particular a speed and/or a spatialposition, of the second embossing tool and/or of the transfer filmand/or of a transport device for transporting the at least one furthersubstrate is regulated by means of the second control data.

It is particularly preferred if the transfer film is fed from a transferfilm storage means in the form of a first film cartridge to the firstembossing tool and after the first embossing operation is wound with aconstant film tension onto a transfer film take-up means in the form ofa second film cartridge. In that case the transfer film storage means isformed in particular by a first film cartridge and the transfer filmtake-up means is formed in particular by a second film cartridge, whicheach include an annular core and two cover plates, so that the transferfilm can be wound around the core and is laterally confined by arespective one of the two cover plates. Such a film cartridge is thussimilar to a film reel which permits the used transfer film to be woundon in a particularly uniform and trouble-free fashion, and renewed usethereof.

For that purpose after the first embossing operation the second filmcartridge onto which the transfer film inclusive of the first openingswas wound is used as the transfer film storage means for performing theat least one further embossing operation. The empty first film cartridgein contrast is used as the transfer film take-up means. For that purposethe position of the first and second film cartridges is easilyinterchanged on the apparatus.

Preferably the apparatus has a respective drive motor for the regulateddrive of the first and second film cartridges to unwind the transferfilm on the transfer film storage means and to wind it on at thetransfer film take-up means.

Embossable materials such as paper, plastic material or laminatescontaining paper and/or plastic film have proven desirable assubstrates.

It is particularly preferred if the at least one substrate and the atleast one further substrate are respectively formed by a card, inparticular a bankcard, a credit card, a telephone card, a drivinglicense card, an identity card, a lottery card or a gift card.

The first and second regions of the transfer layer portion of thetransfer film can be permanently fixed on the respective substrate bymeans of embossing. That is usual in particular for forming securityelements which should no longer be detachable such as for examplesecurity elements with holographic representations, codings, corporatelogos and the like. The first and second regions of the transfer layerportion of the transfer film however can also be arranged by means ofembossing on the substrate in the form of a covering which can be atleast partially scratched off. That is usual for example for lotterytickets in which win information is to be optically masked by aremovable cover layer.

To form a winding which is as uniform as possible of used transfer film,it has proven desirable if the apparatus has between the embossing tooland the transfer film take-up means a first transfer film tensioningdevice which keeps the film tension of the transfer film constant in theregion between the embossing tool and the transfer film take-up means,in particular a first transfer film tensioning device which includes amovable first tensioning roller or first dancer roller. The term“movable” is used here to mean that the position of the axis of rotationof the tensioning or dancer roller can be altered.

It is further advantageous if there is arranged between the transferfilm storage means and the second sensor unit a second transfer filmtensioning device which keeps the film tension of the transfer filmconstant in the region between the transfer film storage means and theembossing tool, in particular a second transfer film tensioning devicewhich includes a movable second tensioning roller or second dancerroller. The term “movable” is used here to mean that the position of theaxis of rotation of the tensioning or dancer roller can be altered.

In that respect a position of the first and/or second tensioning rolleror dancer roller is preferably pneumatically variable.

In particular there is a control unit for controlling the position ofthe first and/or second tensioning roller or dancer roller.

The embossing tool of the apparatus is preferably in the form of anembossing wheel which permits a rolling embossing procedure to beperformed. To drive the embossing wheel, it has been found desirable toprovide a servomotor or an operatively driving coupling to the drive ofthe transport device for transporting the substrates and to regulate thespeed of the embossing wheel in accordance with the settings provided bythe first or second control data.

The embossing wheel is in particular so arranged that it is opposite acounterpressure or backing roller. The embossing tool and/or thecounterpressure roller are preferably heatable, in particular whenperforming a hot embossing method.

To increase the embossing speed it is preferable if at least one coolingdevice is arranged between the embossing tool and the transfer filmtake-up means of the apparatus, for cooling at least the first and/orsecond regions of the transfer film. The at least one cooling devicepreferably includes a blower.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 through 5 are intended to describe by way of example the methodaccording to the invention and the apparatus according to the inventionby reference to a card embossing method. In the drawing:

FIG. 1 diagrammatically shows a transfer film in the first embossingoperation,

FIG. 2 shows the transfer film of FIG. 1 in a further embossingoperation,

FIG. 3 a shows the transfer film after the two embossing operations ofFIGS. 1 and 2,

FIG. 3 b shows the further substrates 2′ after the further embossingoperation,

FIG. 4 shows a diagrammatic side view of an apparatus for performing themethod steps performed in FIGS. 1 and 2, and

FIG. 5 shows a portion W from the apparatus of FIG. 4 in the region ofthe second sensor unit.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 diagrammatically shows a transfer film 1 in the first embossingoperation in which substrates 2 in the form of cards are to be embossedupon. The substrates 2 are arranged in succession in a row. Arrangedabove the substrates 2 is a transfer film 1 in band form, which has acarrier film 1 a and a transfer layer portion 1 b which is not visiblein this view (see FIG. 3 a) on the side of the carrier film 1 a, that istowards the substrates 2. In the first regions 10, the position of whichon the transfer film 1 is indicated here by solid rectangular line thetransfer layer portion 1 b is embossed onto the substrates 2, in whichcase the first regions 10 are respectively disposed on the transfer film1 spaced from each other at the constant spacing a. In the operation ofembossing the first regions 10 out of the transfer layer portion 1 bonto the substrates 2, a respective first opening 10 a is produced inthe transfer layer portion 1 b of the transfer film 1 (see FIGS. 2 and 3a). After the first embossing operation the transfer film 1 is wound upin a uniform, regulated fashion.

FIG. 2 now diagrammatically shows the transfer film 1 of FIG. 1 in thesecond embossing operation in which further substrates 2′ in the form ofcards are to be embossed upon. The substrates 2′ are arranged insuccession in a row. Disposed above the substrates 2′ is the transferfilm 1 which in the form of a band and which has the carrier film 1 aand the transfer layer portion 1 b which is not visible in this view(see FIG. 3 a), on the side of the carrier film 1 a that is towards thesubstrates 2′. The transfer layer portion 1 b is embossed onto thesubstrates 2′ in the second regions 11, the position of which on thetransfer film 1 is indicated here by broken rectangular line, the secondregions 11 being disposed between the first openings 10 a produced inthe first embossing operation in the transfer layer portion 1 b on thetransfer film 1. The position of the first openings 10 a in the transferlayer portion 1 b of the transfer film 1 is indicated in this view byhatched areas.

In the operation of embossing the second regions 11 onto the substrates2′, second openings 11 a are produced in the transfer layer portion 1 bof the transfer film 1 (see FIG. 3 a).

FIG. 3 a shows the transfer film 1 after the first and further embossingoperations viewed from the side in FIGS. 1 and 2, on which the transferlayer portion 1 b is disposed. The transfer layer portion 1 b has firstopenings 10 a which were formed during the first embossing operation andalso second openings 11 a which were formed during the further embossingoperation. The first openings 10 a and the second openings 11 a give afree view onto the carrier film 1 a.

FIG. 3 b shows the further substrates 2′ which as shown in FIG. 2 wereembossed upon with the second regions 11 of the transfer layer portion 1b of the transfer film 1 after removal of the transfer film 1.

FIG. 4 shows an apparatus for carrying out the method steps performed inaccordance with FIGS. 1 and 2, as a diagrammatic side view. The transferfilm 1 is provided by way of a transfer film storage means 3 in the formof a first film cartridge driven in rotation by means of a motor,wherein the transfer film 1 is wound onto the core 3 b of the first filmcartridge, the core 3 b being disposed between the cover plates 3 a, andis fed to the second sensor unit 8 by way of a second transfer filmtensioning device which includes a second dancer roller 9 b and whichkeeps the transfer film tension constant. After the second sensor unit 8the transfer film 1 passes to a pulling mechanism 14 driven by means ofa servomotor, and to the contact pressure roller 15.

From there the transfer film 1 is fed to an embossing tool 5 in the formof a segmented embossing wheel, the contact pressure force of which inrelation to a counterpressure or backing roller 6 can be regulated byway of an embossing cylinder 13 involving stroke adjustment. Thetransfer film 1 and the substrates 2 (not shown here) are conveyedthrough between the embossing tool 5 and the counterpressure roller 6for carrying out the first embossing operation. The embossing tool 5 isheatable by means of a heating hood 16. Segment adjustment 17 serves foradjusting the position of the area to be embossed on a substrate in thelongitudinal direction thereof. The first regions 10 of the transferlayer portion 1 b of the transfer film (see FIGS. 1 through 3) are fixedto a respective one of the substrates 2 by means of the embossing tool 5during a first passage of the transfer film 1 through the apparatus.Downstream of the embossing tool 5 the composite assembly comprising thesubstrate 2 and the transfer film 1 is fed jointly to a cooling device12 and then the transfer film 1 is pulled off the embossed substrate 2.A first region 10 of the transfer layer portion 1 b remains fixed toeach substrate 2. The transfer film 1 inclusive of the first openings 10a is now fed to the transfer film take-up means 4 in the form of asecond film cartridge driven in rotation by means of a motor, by way ofa first sensor unit 7 and a first transfer film tensioning device whichincludes a dancer roller 9 a and which keeps the transfer film tensionconstant, and is wound onto the core 4 b of the second film cartridgewhich is between the cover plates 4 a. During the first embossingoperation the first sensor unit 7 by means of an optical sensor detectsthe position of the first openings 10 a in the transfer layer portion 1b of the transfer film 1 and produces first control data, by means ofwhich a sequence of movements of the embossing tool 5 and/or thetransfer film 1 and/or a transport unit which is not shown here, forexample in the form of a transport chain, for transporting thesubstrates 2 is regulated in such a way that the spacing a between thefirst openings 10 a remains constant or at least substantially constant.After the second embossing operation is performed the second filmcartridge of the transfer film take-up means 4 inclusive of the transferfilm 1 which now has the first openings 10 a is exchanged with the emptyfirst film cartridge of the transfer film storage means 3 and a renewedrun of the transfer film 1 through the apparatus is started forperforming a further embossing operation. Now, in the region of thesecond sensor unit 8, the position of the first openings 10 a isdetected by means of optical sensors 8 a, 8 b and the position of thesecond regions 11 of the transfer layer portion 1 b, which are to berespectively stamped out between two adjacent first openings 10 a, isascertained by means of a third optical sensor 8 c (see FIG. 5).Accordingly, during the second embossing operation, the second sensorunit 8 by means of three optical sensors detects the position of thefirst openings 10 a in the transfer layer portion 1 b of the transferfilm 1 and regulates the sequence of movements of the embossing tool 5and/or the transfer film 1 and/or the transport unit which is not shownhere, for example in the form of a transport chain, for transportationof the further substrates 2′ in such a way that the first openings 10 ado not overlap with the second regions 11 and a spacing a is maintainedbetween each first opening 10 a and a second region 11 of at least 0.5mm. After the second regions 11 are stamped out onto the furthersubstrates 2′ by the embossing tool 5, that is followed by cooling andseparation of the transfer film and the further substrates 2′, asalready described in relation to the first embossing operation. Thetransfer film 1 which now has the first openings 10 a and the secondopenings 11 a is wound onto the film cartridge of the transfer filmtake-up means 4.

The following settings for embossing of the card-form substrates 2, 2′are used for example:

Process speed 25000 card-form substrates 2, 2′ per hour Length of acard-form substrates 2, 2′ 85.6 mm Chain pitch of the transport chainfor 88.9 mm transporting the substrates 2, 2′ Width of the transfer film10 mm Dimensions of the first/second regions 8 mm × 35 mm Area of thefirst/second regions 280 mm² Transfer film consumption per hour 22225 m²Transfer film consumption per substrate 2 889 mm² when carrying out onlya first embossing operation Degree of use of the transfer film in only31.49% one embossing operation Transfer film consumption per substrate2′ 444.5 mm² when carrying out a further embossing operation Degree ofuse of the transfer film in two 63% embossing operations

The costs of the transfer film are reduced accordingly by 41% by virtueof the double use of the transfer film for carrying out a first and afurther embossing operation.

FIG. 5 shows the portion W of the FIG. 4 apparatus, in which the secondsensor device 8 is disposed, but without the transfer film 1. Thetransfer film 1 which already has the first openings 10 a in thetransfer layer portion 1 b of the transfer film 1 is shown to the rightbeside the second sensor unit 8, to better illustrate the mode ofoperation thereof. The second sensor unit 8 has three optical sensors 8a, 8 b, 8 c, wherein the two sensors 8 a and 8 b detect the position ofthe first openings 10 a in the transfer layer portion 1 b of thetransfer film 1 during the second embossing operation. The sensor 8 cserves to determine the position of the second region 11 which is stillto be stamped out. The three sensors 8 a, 8 b, 8 c form second controldata which are used to regulate the movements of the embossing tool 5and/or the transfer film 1 and/or a transport unit for transporting thefurther substrates 2′, in such a way that the first openings 10 a do notoverlap with the second regions 11 and a spacing is maintained betweenfirst opening 10 a and a second region 11 of at least 0.5 mm.

It will be appreciated that the method according to the invention can beused not only for embossing card-form substrates, but it is suitable forall embossing procedures in which a transfer film was only inadequatelyused after the first embossing operation and sufficiently large regionsof the transfer layer portion have remained on the carrier film to beable to carry out a further embossing operation with the transfer filmwhich has already been used.

LIST OF REFERENCES

-   1 transfer film-   1 a carrier film of the transfer film-   1 b transfer layer portion of the transfer film-   2 substrate in card form-   2′ further substrate in card form-   10 first regions of the transfer layer portion-   10 a first openings in the transfer layer portion-   11 second regions of transfer layer portion-   11 a second openings in the transfer layer portion-   3 transfer film storage means in the form of a first film cartridge-   3 a cover plates of the first film cartridge-   3 b core of the first film cartridge-   4 transfer film take-up means in the form of a second film cartridge-   4 a cover plates of the second film cartridge-   4 b core of the second film cartridge-   5 embossing tool-   6 counterpressure roller-   7 first sensor unit-   8 second sensor unit-   8 a, 8 b, 8 c sensors of the second sensor unit-   9 a first dancer roller of the first transfer film tensioning device-   9 b second dancer roller of the second transfer film tensioning    device-   12 cooling device-   13 embossing cylinder with stroke adjustment-   14 pulling mechanism with servomotor drive-   15 contact pressure roller-   16 heating hood-   17 segment adjustment

The invention claimed is:
 1. A method of embossing with increasedoutput, the method comprising steps of: feeding a transfer film in woundform from a first film storage means to an embossing tool, the transferfilm having a carrier film and a transfer layer portion which isreleasable from the carrier film; feeding a plurality of individualcards to the embossing tool, the cards being arranged in succession in arow; embossing first regions of the transfer layer portion, which arearranged removed from each other at a spacing a, from the transfer filmonto respective first cards of the plurality of individual cards withthe embossing tool during a first embossing operation, wherein the firstregions are removed from the transfer film to produce first openings atthe spacing a in the transfer layer portion of the transfer film;winding the transfer film up after the first embossing operation;feeding the transfer film wound up after the first embossing operationto the same embossing tool used in the first embossing operation for asecond embossing operation; detecting a position of the first openingsin the transfer layer portion of the wound transfer film with twosensors of a second embossing operation sensor unit; determining aposition of second openings to be formed in the transfer layer portionin adjacent relationship with the first openings using a third sensor ofthe second embossing operation sensor unit, the second embossingoperation sensor unit generating control data for regulating movement ofat least one of the transfer film, the individual cards and theembossing tool; and embossing second regions of the transfer layerportion onto respective second cards of the plurality of individualcards with the embossing tool during the second embossing operation,regulated based on the control data generated by the second embossingoperation sensor unit wherein each second region is removed from thetransfer film between two first openings to produce second openings inthe transfer layer portion of the transfer film arranged at a spacingfrom the first openings, wherein the transfer film is fed from the firstfilm storage means in the form of a first film cartridge to theembossing tool and after the first embossing operation is wound with aconstant film tension onto a transfer film take-up means in the form ofa second film cartridge, and wherein, after the first embossingoperation, the second film cartridge onto which the transfer filminclusive of the first openings was wound is used as a transfer filmstorage means for performing the second embossing operation.
 2. A methodas set forth in claim 1, wherein the spacing a is kept constant over theentire length of the transfer film.
 3. A method as set forth in claim 1,wherein, prior to winding the transfer film up after the first embossingoperation, a position of the first openings in the transfer layerportion of the transfer film is detected in a first embossing operationsensor unit in the form of first control data by means of at least onefirst sensor.
 4. A method as set forth in claim 3, wherein, during thefirst embossing operation, a sequence of movements of the firstembossing tool and/or of the transfer film and/or of a transport devicefor transporting the first cards of the plurality of individual cards isregulated by means of the first control data.
 5. A method as set forthin claim 4, wherein a speed and/or a spatial position of the firstembossing tool and/or of the transfer film and/or the transport deviceis regulated by means of the first control data.
 6. A method as setforth in claim 1, wherein, after the first embossing operation, thefirst film cartridge is used as a transfer film take-up means for thesecond embossing operation.
 7. A method as set forth in claim 1, whereina first opening and an adjacent second opening are formed at a spacingfrom each other of at least 0.5 mm.
 8. A method as set forth in claim 1,wherein the plurality of individual cards all have equal dimensions. 9.A method as set forth in claim 1, wherein the first openings and thesecond openings are of equal size.
 10. A method as set forth in claim 1,wherein the plurality of cards are arranged in succession in a row witha gap between each successive card.